A continuously curving cleaning element and method of making

ABSTRACT

The curved cleaning element is made by providing a cleaning material with a back surface and a working surface that together define a volume and thickness. A portion of the cleaning material is removed at a pivot zone. The pivot zone separates the cleaning material into a first portion and second portion. At the pivot zone, the cleaning material has less thickness and/or less volume as compared to either the first or second portions. In one embodiment, the back surface of the first portion of the cleaning material is attached to a support and the second portion of the cleaning material is pivoted at the pivot zone. The second portion of the cleaning material is secured to either the support or the first portion of the cleaning material to form a continuously curving working surface of the cleaning material.

FIELD

The present disclosure relates to a continuously curving cleaning element and a method of making a continuously curving cleaning element.

BACKGROUND

Cleaning tools are commonly used for cleaning dishes, bathrooms, walls, showers. These tools can be made of various materials such as foam, sponge, fabric, scrubbing webs and may be attached to a solid, handled tool. Examples of commonly used cleaning tools include the Scotch-Brite™ Scrub Sponge and Scotch-Brite™ Dishwand. These tools include generally flat working surfaces. However, depending on the substrate to be cleaned, it may be desirable to have a cleaning tool with a continuously curving surface. Depending on the construction of the cleaning tool, folding, bending, or curving the tool may place stresses within the tool that result in the tool preferentially returning to a flat working surface.

SUMMARY

The disclosed cleaning element and method of making the disclosed cleaning element allow for a continuously curving working surface with minimal internal stresses on the curved cleaning element. Therefore, the continuously curving cleaning element maintains its shape under use and allows for easy cleaning of flat and curved surfaces.

In one embodiment, the method of making a curving cleaning element comprises providing a cleaning material with a back surface and a working surface, removing a portion of the cleaning material at a pivot zone, wherein the pivot zone separates the cleaning material into a first portion and second portion, securing the back surface of the first portion of the cleaning material to a support, pivoting the second portion of the cleaning material at the pivot zone, securing the second portion of the cleaning material to either the support or the first portion of the cleaning material, and forming a continuously curving working surface of the cleaning material.

In one embodiment, the back surface of the cleaning material comprises a foam or a scouring web. In one embodiment, the cleaning material comprises a working surface comprised of woven, knitted, or nonwoven fabric, scouring material, scouring web. In one embodiment, the cleaning material comprises of more than one layer. In one embodiment, the removing comprises melting a portion of the cleaning material at a pivot zone. In one embodiment, the removing comprises cutting a portion of the cleaning material at the pivot zone. In one embodiment, the removing comprises compressing a portion of the cleaning material at a pivot zone. In one embodiment, the removing comprises removing a generally linear portion of the cleaning material from within the cleaning material. In one embodiment, the removing comprises removing a generally linear portion, recessed within a perimeter of the cleaning material, from within the cleaning material. In one embodiment, the pivot zone comprises a pivot axis, which extends through the cleaning material. In one embodiment, the securing is by one of mechanically securing, adhesively securing, thermally melting securing. In one embodiment, the method comprises pivoting the second portion of the cleaning material at least 45 degrees and less than 180 degrees, as measured by the angle formed through the cleaning material. In one embodiment, the method comprises securing the back surface of the second portion of the cleaning material to a second portion of the support. In one embodiment, the method further comprises securing a handle to the support.

In one embodiment, a curving cleaning element comprises a cleaning material with back surface and a working surface defining a perimeter and a volume, a pivot zone comprising a portion of reduced thickness and reduced volume of cleaning material, wherein the cleaning material pivots about the pivot zone and the working surface is continuously curving.

In one embodiment, the pivot zone portion of reduced thickness and reduced volume is within the perimeter of the cleaning material. In one embodiment, the cleaning element further comprises a support that secures to the back surface of the cleaning material. In one embodiment, the pivot zone separates a first portion of cleaning material from a second portion of cleaning material, the back surface of the first portion is secured to a support, the second portion is secured to either the support or the first portion of the cleaning material. In one embodiment, the cleaning material at the back surface is a conformable, thermoplastic material. In one embodiment, the portion of reduced thickness and volume is a melted section of the conformable, thermoplastic material, and the melted section is surrounded by sloping inward surfaces. In one embodiment, the cleaning material comprises a two layer structure of a foam and a scouring material at the working surface. In one embodiment, the cleaning element further comprises a handle connected to the support. In one embodiment, at the pivot zone, the cleaning material at the back surface is under compression and the cleaning material at the working surface is under tension.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a cleaning element;

FIG. 2 is a sectional view of the cleaning element shown in FIG. 1 through line 2-2;

FIG. 3 is a perspective view of the cleaning element of FIG. 1 with a support;

FIG. 4 is a perspective view of a cleaning tool comprising the cleaning element of FIG. 1 with a continuously curving surface;

FIG. 5 is a perspective view of a second embodiment of a cleaning element;

FIG. 6 is a perspective view of the cleaning element shown in FIG. 5 with a continuously curving surface.

While the above-identified drawings and figures set forth embodiments of the invention, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of this invention.

The figures may not be drawn to scale.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of one embodiment of a cleaning element 300. FIG. 2 is a sectional view of the cleaning element 300 shown in FIG. 1 through line 2-2. FIG. 3 is a perspective view of the cleaning element 300 of FIG. 1 with a support 310. FIG. 4 is a perspective view of a cleaning tool 100 comprising the cleaning element 300 of FIG. 1.

In the embodiment shown in FIG. 4, the cleaning tool 100 comprises a handle 200 with a holding end 205 and a working end 210. The working end 210 includes a first attachment 230 for connection with a second attachment 311(discussed below) on the cleaning element 300. In one embodiment the handle 200 includes a receptacle 215 for holding a liquid, such as liquid dish soap. To aid in dispensing the dish soap from the receptacle 215 to the cleaning element 300, the handle includes a passage 217. In one embodiment, to prevent continuous leaking of the liquid contained within the receptacle, the handle may include a valve (not shown) at the passage 217 to hold the liquid in the handle until sufficient pressure is placed against the valve. The pressure may come from deformation of an actuator 220. In this embodiment, the actuator 220 is deformable and is located on the underside of the handle 200. Therefore, when the handle 200 is being held, a user's index finger is able to easily deform the actuator 220, which in turn, forces liquid from the valve out the passage 217. From the passage 217, the liquid will enter into the cleaning element 300. The cleaning element 300 may itself include through passages to further aid in the fast release of the dispensed liquid from the handle 200 to the surface being cleaned.

The cleaning element 300 includes a cleaning material 305 with a working surface 330, a back surface 340, defining a perimeter 302, width 301, thickness 303, and volume. The cleaning element 300 includes a first portion 314 and a second portion 317 separated from one another by a pivot zone 320. The second portion 317 is able to rotate relative to the first portion 314 at the pivot zone 320. In one embodiment, the pivot zone 320 includes a pivot axis 322, which passes through the cleaning element 300 so that the second portion 317 is able to rotate relative to the first portion 314 about the pivot axis 322. The pivoting or rotation of the second portion 317 relative to the first portion 314 creates the continuously curving working surface 330. By continuously curving, it is meant that the cleaning material 305 at the working surface 330 does not have breaks or disconnects, other than those features naturally part of the underlying substrate.

When the cleaning element 300 is of a completely uniform, solid material, pivoting a second portion relative to the first portion can apply large amounts of pressure and stress on the cleaning element 300 due to the compressed cleaning material at the pivot. Removing or reducing a portion of the cleaning material at the pivot, while keeping the working surface continuous, allows for reduced stress on the cleaning element. Therefore, the pivoted cleaning material remains in a pivoted position.

In one embodiment, cleaning material 305 at the pivot zone 320 is removed. In one embodiment, the pivot zone 320 is a portion of the cleaning element 300 having a thickness less than the thickness of either the first or second portions 314, 317. In one embodiment, the pivot zone 320 is a portion of the cleaning element 300 having a volume less than the volume of either the first or second portions 314, 317. In one embodiment, the pivot zone 320 is a portion of the cleaning element 300 having a density that is less than the density of either the first or second portions 314, 317. In either embodiment, the cleaning material 305 at the working surface 330 remains continuous.

The pivot zone 320 is created by removing a portion of the cleaning material 305. Creating the pivot zone 320 on the cleaning material 305 can be accomplished from a variety of known techniques to remove material depending on the type of cleaning material 305 and the desired configuration of the shape or arrangement of the removed material at the pivot zone 320. To remove cleaning material 305 to create the pivot zone 320, cleaning material 305 can be melted, compressed, dissolved, or mechanically cut. For example, techniques such as water jet cutting, notching, variable cross sectioning, laser cutting, routing, knife cutting, flame melting, chemical melting or fusing, band heating, or hot wire melting or cutting from application of heat could be used to form the pivot zone 320. One skilled in the art would be able to identify suitable techniques for the particular cleaning material 305. For example, melting is a suitable technique for forming the pivot zone for thermoplastic cleaning material, such as thermoplastic foams or nonwovens.

There can be any number of arrangements for the specific arrangement of the pivot zone 320, i.e., the material removed from the cleaning material 305 to form the pivot zone 320. Generally, the material removed from the cleaning material 305 to create the pivot zone 320 is shaped to guide curving and pivoting of the second portion 317 relative to the first portion 314. To maintain the continuity and integrity of the working surface 330, the pivot zone 320 does not extend entirely through the thickness 303 of the cleaning material 305. There may be one or more defined portions removed from the cleaning material 305 to form the pivot zone 320.

In the embodiment shown in FIGS. 1, 2 and 3, the pivot zone 320 extends across the width 301 of the cleaning material 305, but near the perimeter 302 some cleaning material 305 remains. The thickness of the material removed at the perimeter 302 of the pivot zone 320 is less than the thickness of the material removed within the remaining portion of the pivot zone 320, which is less than the overall thickness 303 of the cleaning material 305. In other words, material removed at the pivot zone 320 is not uniform across the width 301 of the cleaning material 305. In this embodiment, when the second portion 317 is curved relative to the first portion 314, the cleaning material 305 at the perimeter 302 remains to provide a nearly continuous surface without substantial gaps or openings.

In the embodiment shown in FIGS. 5 and 6, the pivot zone 320 extends uniformly and entirely across the width 301 of the cleaning material 305. In one embodiment, not shown, the cleaning material removed to form the pivot zone 320 is entirely within the perimeter 302 of the cleaning material 305, such that at the perimeter 302 the full thickness 303 of the cleaning material 305 remains.

In the specific embodiment shown in FIGS. 1-4, the cleaning material 305 is a thermoplastic, specifically a thermoplastic foam, and the pivot zone 320 is formed by melting the thermoplastic material to create a generally inward sloping surface at the pivot zone 320. The inward sloping surface at the pivot zone 320 creates a pull or pucker so that the second portion 317 naturally pivots relative to the first portion 314.

The pivot zone 320 may include one or more linear, circular, or other shaped sections removed. In one embodiment, more than 10% of the thickness at the pivot zone is removed, in one embodiment, more than 25% of the thickness at the pivot zone is removed, and in one embodiment more than 50% of the thickness at the pivot zone is removed. In one embodiment, more than 5% of the thickness remains at the working surface, in one embodiment, more than 15% of the thickness remains at the working surface, in one embodiment, more than 25% of the thickness remains at the working surface.

In one embodiment, the working surface 330 of cleaning material 305 continuously curves at least 45 degrees, as measured by an inside angle formed through the cleaning material 305 between the relative positions of the working surface 330. In one embodiment, the working surface 330 of cleaning material 305 continuously curves at least 90 degrees, as measured by an inside angle formed through the cleaning material 305 between the relative positions of the working surface 330. In one embodiment, the working surface 330 of cleaning material 305 continuously curves less than 180 degrees, as measured by an inside angle formed through the cleaning material 305 between the relative positions of the working surface 330. In one embodiment, relative portions of the working surface 330 are parallel to one another, but spaced apart from one another by the cleaning material 305.

It is understood that to create the disclosed continuously curving working surface 330, the second portion 317 of the cleaning material 305 rotates relative to the first portion 314 such that at the back surface 340 of the cleaning material 305 is at least partially under compression while the cleaning material 305 at the working surface 330 is at least partially under tension.

The cleaning material 305 may have varying width 301 along its length. In one embodiment, as can best be seen in FIGS. 1 and 3, the cleaning material at the first portion 314 has a first width wider than the width at the second portion 317. Therefore, the width of the working surface 330 narrows at the pivot zone 320. Therefore, the working surface 330 at the pivot zone 320 is better able to fit into small, curving areas of items being clean, like the bottom of a glass or bowl.

In one embodiment, the cleaning element 300, such as shown in FIG. 1, can be used alone as shown. The second portion 317 can flex and pivot at the pivot zone 320 relative to the first portion 314 to allow for cleaning of contoured surfaces.

In one embodiment, the cleaning element 300 may be secured to a support 310. The support 310 maybe secured to one or both of the first and second portions 314, 317. The support 310 may be secured to a back surface 340 of the first portion 314, the second portion 317 pivoted and then secured either to the support 310 or to a portion of the back surface 340 of the first portion, such as shown in FIG. 3. The support maybe secured to both the first and second portions and would include a flexible portion at the pivot zone 320, such as a living hinge, or such as shown in US Patent Application Publication 2014-0013527, incorporated herein by reference. In one embodiment, the support 310 may be of a size or shape to allow a user to easily hold the cleaning element 300.

In one embodiment, the support includes the second attachment 311 with a slot 312 for receiving the first attachment 230 of the handle 200. The second attachment 311 also includes a guard 313. The guard 313 is deformable so that is can be pressed down to allow for the first attachment 230 to slide in and out of the second attachment 311. When the guard 313 is in place, it securely wraps around the backside of the working end 210 of the handle 200 to provide a secure connection between the cleaning element 300 and handle 200.

Depending on the materials of the support 310 or the cleaning material 305, one skilled in the art could use any number of materials or techniques for either securing the cleaning element 300 to the support or for securing the second portion 317 of the cleaning material 305 to either the support 310 or the first portion 314 to create the continuously curving working surface 330. For example, chemical or flame treatment of a meltable material, adhesives, or mechanical fasteners could be used. In one embodiment, as shown in FIG. 3 a support 310 is secured to the back surface 340 of the first portion 314 of the cleaning material 305, while the second portion 317 is rotated about the pivot zone 320 and secured to a portion of the support 310. In another embodiment, a portion of a support is secured to the first portion 314 of the cleaning material 305 while a second portion of a support is secured to the second portion 317 of the cleaning material 305. The two parts of the support interact and may interlock such as described in US Patent Application Publication 2014-0013527.

The cleaning material 305 can comprise foam, sponge, nonwoven fabric, knitted fabric, woven fabric, scouring material, such as scouring nonwoven webs or fabric coated or printed with abrasive or resin, or combinations of one or more thereof. In one embodiment, the cleaning material 305 is a foam or sponge, with a scouring layer secured to the foam or sponge at the outermost working surfaces. The cleaning material 305 can be secured to the support 310 by a variety of mechanisms such as adhesive or melt bonding.

It is understood that the curved cleaning element 300 may be secured to a separate cleaning tool 100, which includes a handle, or may be independently used for cleaning. Further if used with a cleaning tool 100, any variety of sizes and shapes of cleaning tools could be used and any specific types of attachment mechanisms could be used for securing the cleaning element 300 to the cleaning tool 100.

FIGS. 5 and 6 show an alternative embodiment, where similar reference numbers for similar features are used. As distinguished from the embodiment shown in FIGS. 1-4, in this embodiment the pivot zone 320 includes a shaped section from edge-to-edge of the cleaning material 305. In the pivoted cleaning element 300 shown in FIG. 6, the second portion 317 is secured to the back surface 340 of the first portion 314. A support is not shown, but it is understood that a support such as described above could be included. In this embodiment, the working surface 330 is continuously curving.

The cleaning element 300 can be made in a variety of methods disclosed. In one embodiment, the cleaning element 300 is made by providing a cleaning material 305 with back surface 340 and a working surface 330 that together define a volume and thickness 303. A portion of the cleaning material 305 is removed at a pivot zone 320. The pivot zone 320 separates the cleaning material 305 into a first portion 314 and second portion 317. At the pivot zone 320, the cleaning material 305 has less thickness and/or less volume as compared to either the first or second portions 314, 317. In one embodiment, the back surface 340 of the first portion 314 of the cleaning material 305 is attached to a support 310 and the second portion 317 of the cleaning material 305 is pivoted at the pivot zone. The second portion 317 of the cleaning material 305 is secured to the support 310 and/or the first portion 314 of the cleaning material 305 to form a continuously curving working surface 330 of the cleaning material 305.

The disclosed curved cleaning element and method of making the cleaning element provide for a continuously curving working surface that is useful for cleaning flat and curved surfaces such as bowls or cups.

Although specific embodiments of this invention have been shown and described herein, it is understood that these embodiments are merely illustrative of the many possible specific arrangements that can be devised in application of the principles of the invention. Numerous and varied other arrangements can be devised in accordance with these principles by those of skill in the art without departing from the spirit and scope of the invention. Thus, the scope of the present invention should not be limited to the structures described in this application, but only by the structures described by the language of the claims and the equivalents of those structures. 

What is claimed is:
 1. A method of making a curving cleaning element comprising: providing a cleaning material with back surface and a working surface; removing a portion of the cleaning material at a pivot zone, wherein the pivot zone separates the cleaning material into a first portion and second portion; securing the back surface of the first portion of the cleaning material to a support; pivoting the second portion of the cleaning material at the pivot zone; securing the second portion of the cleaning material to either the support or the first portion of the cleaning material; forming a continuously curving working surface of the cleaning material.
 2. The method of claim 1, wherein the back surface of the cleaning material comprises a foam or a scouring web.
 3. The method of claim 1, wherein the cleaning material comprises a working surface comprised of woven, knitted, or nonwoven fabric, scouring material, scouring web.
 4. The method of claim 1, wherein the cleaning material is comprises of more than one layer.
 5. The method of claim 1, wherein the removing comprises: melting a portion of the cleaning material at a pivot zone.
 6. The method of claim 1, wherein the removing comprises: cutting a portion of the cleaning material at the pivot zone.
 7. The method of claim 1, wherein the removing comprises: compressing a portion of the cleaning material at a pivot zone.
 8. The method of claim 1, wherein the removing comprises: removing a generally linear portion of the cleaning material from within the cleaning material.
 9. The method of claim 1, wherein the removing comprises: removing a generally linear portion, recessed within a perimeter of the cleaning material, from within the cleaning material.
 10. The method of claim 1, wherein the pivot zone comprises a pivot axis, which extends through the cleaning material.
 11. The method of claim 1, wherein the securing is by one of mechanically securing, adhesively securing, thermally melting securing.
 12. The method of claim 1, wherein pivoting the working surface at the second portion is at less than 180 degrees, as measured by an inside angle formed through the cleaning material between the relative positions of the working surface.
 13. The method of claim 1, further comprising: securing the back surface of the second portion of the cleaning material to a second portion of the support.
 14. The method of claim 1, further comprising: securing a handle to the support.
 15. A curving cleaning element comprising: a cleaning material with back surface and a working surface defining a perimeter and a volume; a pivot zone comprising a portion of reduced thickness and reduced volume of cleaning material; wherein the cleaning material pivots about the pivot zone; wherein the working surface is continuously curving.
 16. The curving cleaning element of claim 15, wherein the pivot zone portion of reduced thickness and reduced volume is within the perimeter of the cleaning material.
 17. The curving element of claim 15, further comprising a support that secures to the back surface of the cleaning material.
 18. The curving element of claim 15, wherein: the pivot zone separates a first portion of cleaning material from a second portion of cleaning material; the back surface of the first portion is secured to a support; the second portion is secured to either the support or the first portion of the cleaning material.
 19. The curving cleaning element of claim 15, wherein the cleaning material at the back surface is a conformable, thermoplastic material.
 20. The curving cleaning element of claim 19, wherein the portion of reduced thickness and volume is a melted section of the conformable, thermoplastic material, and wherein the melted section is surrounded by sloping inward surfaces.
 21. The curving cleaning element of claim 15, wherein the cleaning material comprises a two layer structure of a foam and a scouring material at the working surface.
 22. The curving cleaning element of claim 17, further comprising: a handle connected to the support.
 23. The curving cleaning element of claim 15, wherein at the pivot zone, the cleaning material at the back surface is under compression and the cleaning material at the working surface is under tension. 